Methods of recovering hydrocarbons from hydrocarbonaceous material using a constructed infrastructure having permeable walls and associated systems

ABSTRACT

A method of recovering hydrocarbons from hydrocarbonaceous materials can include forming a constructed permeability control infrastructure. This constructed infrastructure defines a substantially encapsulated volume having substantially permeable side walls and a substantially impermeable cap. A comminuted hydrocarbonaceous material can be introduced into the control infrastructure to form a permeable body of hydrocarbonaceous material. The permeable body can be heated sufficient to remove hydrocarbons therefrom without contamination or substantial leaching of materials outside of the impoundment. During heating the hydrocarbonaceous material is substantially stationary as the constructed infrastructure is a fixed structure. Removed hydrocarbons can be collected for further processing, use in the process, and/or use as recovered.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Nos.60/900,505, filed Feb. 9, 2007; 60/906,634, filed Mar. 12, 2007; and60/930,711, filed May 17, 2007, which are each incorporated herein bythis reference.

BACKGROUND OF THE INVENTION

Global and domestic demand for fossil fuels continues to rise despiteprice increases and other economic and geopolitical concerns. As suchdemand continues to rise, research and investigation into findingadditional economically viable sources of fossil fuels correspondinglyincreases. Historically, many have recognized the vast quantities ofenergy stored in oil shale, coal and tar sand deposits, for example.However, these sources remain a difficult challenge in terms ofeconomically competitive recovery. Canadian tar sands have shown thatsuch efforts can be fruitful, although many challenges still remain,including environmental impact, product quality, and process time, amongothers.

Estimates of world-wide oil shale reserves range from two to almostseven trillion barrels of oil, depending on the estimating source.Regardless, these reserves represent a tremendous volume and remain asubstantially untapped resource. A large number of companies andinvestigators continue to study and test methods of recovering oil fromsuch reserves. In the oil shale industry, methods of extraction haveincluded underground rubble chimneys created by nuclear explosions,in-situ methods such as In-Situ Conversion Process (ICP) method (ShellOil), and combustion within steel fabricated retorts. Other methods haveincluded in-situ radio frequency methods (microwaves), and “modified”in-situ processes wherein underground mining, blasting and retortinghave been combined to make rubble out of a formation to allow for bettercombustion and heating permeability. Permeability is generally desiredbecause pyrolysis, the method by which the hydrocarbons are extracted,can be achieved with greater quality and production with lower energyinput.

Among typical oil shale processes, all face tradeoffs in economics andenvironmental concerns. No current process alone satisfies economic,environmental and technical challenges. Moreover, global warmingconcerns give rise to additional measures to address carbon dioxide(CO₂) emissions which are associated with such processes. Methods areneeded that accomplish environmental stewardship, yet still provide highvolume energy fuel output.

Below ground in-situ concepts emerged based on their ability to producehigh volumes while avoiding the cost of mining. While the cost savingsavoiding mining can be achieved, the in-situ method requires heating aformation for a longer period of time due to the extremely lowpermeability of shale, which by its nature, requires a slower and longerretorting time to fracture and convert hydrocarbons in a formation. Byutilizing the in-situ method, gains can be realized in the volume andmining cost savings, but the in situ method runs into permeabilityproblems requiring formation fracture and longer periods of time toproduce oil and gases. Perhaps the most significant challenge for anyin-situ process is the uncertainty and long term potential of watercontamination that can occur with underground freshwater aquifers. Inthe case of Shell's ICP method, a “freeze wall” is used as a barrier to,in theory, keep separation between aquifers and an underground treatmentarea. Although this is possible, no long term analysis has proven forextended periods to guarantee the prevention of contamination. Withoutguarantees and with even fewer remedies should a freeze wall fail, othermethods are desirable to address such environmental risks.

For this and other reasons, the need remains for methods and systemswhich can provide improved recovery of hydrocarbons from suitablehydrocarbon-containing materials, which have acceptable economics andavoid the drawbacks mentioned above.

SUMMARY OF THE INVENTION

In accordance with the present invention, a method of recoveringhydrocarbons from hydrocarbonaceous materials can include forming aconstructed permeability control infrastructure. This constructedinfrastructure defines a substantially encapsulated volume havingsubstantially permeable side walls (e.g. exposed geological formationsor compacted earth) and a substantially impermeable cap. A minedhydrocarbonaceous material can be introduced into the controlinfrastructure to form a permeable body of hydrocarbonaceous material.The permeable body can be heated sufficient to remove hydrocarbonstherefrom while also avoiding substantial leaching or movement ofmaterials such as hydrocarbon liquids, gases, or leachate outside of theimpoundment. During heating the hydrocarbonaceous material can besubstantially stationary except for subsidence or settling as thematerial is heated. Removed hydrocarbons can be collected for furtherprocessing, use in the process as supplemental fuel or additives, and/ordirect use without further treatment. Depending on the startinghydrocarbon materials, liquid products of high API and good flowabilitycan be readily produced.

The present invention can allow difficult problems to be solved relatedto the extraction of hydrocarbon liquids and gases from surface orunderground mined hydrocarbon bearing deposits and from harvestedbiomass such as oil shale, tar sands, lignite, coal, and biomass. Amongother things, the present invention helps reduce cost, increase volumeoutput, lower air emissions, limit water consumption, preventunderground aquifer contamination, reclaim surface disturbances, reducematerial handling costs, remove dirty fine particulates, and improvecomposition of recovered hydrocarbon liquid or gas. The presentinvention also addresses water contamination issues with a safer, morepredictable, engineered, observable, repairable, adaptable andpreventable water protection structure.

The present invention is an “aboveground” method which ismining-dependent, yet it is not limited or encumbered to conventionalaboveground (ex-situ) retorting processes. This invention improves uponthe benefits of surface retorts including better process control oftemperature, pressure, injection rates, fluid and gas compositions,product quality and better permeability due to processing and heatingmined rubble. These advantages are available in accordance with thepresent invention while still addressing the volume, handling, andscalability issues most fabricated surface retorts cannot provide.

Other improvements which can be realized from the present invention arerelated to environmental protection. Conventional surface retorts havehad the problem of spent shale after it has been mined and has passedthrough a surface retort. Spent shale which has been thermally alteredrequires special handling to reclaim and isolate from surface drainagebasins and underground aquifers. The object of this invention addressesreclamation and retorting in a uniquely combined approach. In regards toair emissions which are also a major problem typical of prior surfaceretort methods, this invention, because of its enormous volume capacityand high permeability, can accommodate longer heating residence timesand therefore lower temperatures. One benefit of lower temperatures inthe extraction process is that carbon dioxide production fromdecomposition of carbonates in the oil shale ore can be substantiallylimited thereby dramatically reducing CO₂ emissions and atmosphericpollutants. This invention uniquely provides solutions to problems fornot just one, but many problems, and in an integrated approach. As aresult, significant benefits to the public can be achieved in terms ofenergy production, economic opportunity, environmental stewardship andenergy output.

Additional features and advantages of the invention will be apparentfrom the following detailed description, which illustrates, by way ofexample, features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is side partial cutaway view schematic of a constructedpermeability control infrastructure in accordance with one embodiment ofthe present invention.

FIG. 2 is a top and plan view of a plurality of permeability controlimpoundments in accordance with one embodiment of the present invention.

FIG. 3 is a side cutaway view of a permeability control impoundment inaccordance with one embodiment of the present invention.

FIG. 4 is a schematic of a portion of a constructed infrastructure inaccordance with an embodiment of the present invention.

FIG. 5 is a schematic showing heat transfer between two permeabilitycontrol impoundments in accordance with another embodiment of thepresent invention.

It should be noted that the figures are merely exemplary of severalembodiments of the present invention and no limitations on the scope ofthe present invention are intended thereby. Further, the figures aregenerally not drawn to scale, but are drafted for purposes ofconvenience and clarity in illustrating various aspects of theinvention.

DETAILED DESCRIPTION

Reference will now be made to exemplary embodiments and specificlanguage will be used herein to describe the same. It will neverthelessbe understood that no limitation of the scope of the invention isthereby intended. Alterations and further modifications of the inventivefeatures described herein, and additional applications of the principlesof the invention as described herein, which would occur to one skilledin the relevant art and having possession of this disclosure, are to beconsidered within the scope of the invention. Further, before particularembodiments of the present invention are disclosed and described, it isto be understood that this invention is not limited to the particularprocess and materials disclosed herein as such may vary to some degree.It is also to be understood that the terminology used herein is used forthe purpose of describing particular embodiments only and is notintended to be limiting, as the scope of the present invention will bedefined only by the appended claims and equivalents thereof.

Definitions

In describing and claiming the present invention, the followingterminology will be used.

The singular forms “a,” “an,” and “the” include plural references unlessthe context clearly dictates otherwise. Thus, for example, reference to“a wall” includes reference to one or more of such structures, “apermeable body” includes reference to one or more of such materials, and“a heating step” refers to one or more of such steps.

As used herein, “below grade” and “subgrade” refer to a foundation ofsupporting soil or earth beneath a constructed structure. Therefore, asrock, soil or other material is removed or excavated from a location,the surface grade level follows the contours of the excavation. Theterms “in situ,” “in formation,” and “subterranean” therefore refer toactivities or locations which are below grade.

As used herein, “conduits” refers to any passageway along a specifieddistance which can be used to transport materials and/or heat from onepoint to another point. Although conduits can generally be circularpipes, other non-circular conduits can also be useful. Conduits canadvantageously be used to either introduce fluids into or extract fluidsfrom the permeable body, convey heat transfer, and/or to transport radiofrequency devices, fuel cell mechanisms, resistance heaters, or otherdevices.

As used herein, “constructed infrastructure” refers to a structure whichis substantially entirely man made, as opposed to freeze walls, sulfurwalls, or other barriers which are formed by modification or fillingpores of an existing geological formation.

The constructed permeability control infrastructure is preferablysubstantially free of undisturbed geological formations, although theinfrastructure can be formed adjacent or in direct contact with anundisturbed formation. Such a control infrastructure can be unattachedor affixed to an undisturbed formation by mechanical means, chemicalmeans or a combination of such means, e.g. bolted into the formationusing anchors, ties, or other suitable hardware.

As used herein, “comminuted” refers to breaking a formation or largermass into pieces. A comminuted mass can be rubbilized or otherwisebroken into fragments.

As used herein, “hydrocarbonaceous material” refers to anyhydrocarbon-containing material from which hydrocarbon products can beextracted or derived. For example, hydrocarbons may be extracteddirectly as a liquid, removed via solvent extraction, directly vaporizedor otherwise removed from the material. However, many hydrocarbonaceousmaterials contain kerogen or bitumen which is converted to a hydrocarbonthrough heating and pyrolysis. Hydrocarbonaceous materials can include,but is not limited to, oil shale, tar sands, coal, lignite, bitumen,peat, and other organic rich rock.

As used herein, “impoundment” refers to a structure designed to hold orretain an accumulation of fluid and/or solid moveable materials. Animpoundment generally derives at least a substantial portion offoundation and structural support from earthen materials. Thus, thecontrol walls of the present invention do not always have independentstrength or structural integrity apart from the earthen material and/orformation against which they are formed.

As used herein, “permeable body” refers to any mass of comminutedhydrocarbonaceous material having a relatively high permeability whichexceeds permeability of a solid undisturbed formation of the samecomposition. Permeable bodies suitable for use in the present inventioncan have greater than about 10% void space and typically have void spacefrom about 20% to 40%, although other ranges may be suitable. Allowingfor high permeability facilitates heating of the body through convectionas the primary heat transfer while also substantially reducing costsassociated with crushing to very small sizes, e.g. below about 1 toabout 0.5 inch.

As used herein, “wall” refers to any constructed feature having apermeability control contribution to confining material within anencapsulated volume defined at least in part by control walls. Walls canbe oriented in any manner such as vertical, although ceilings, floorsand other contours defining the encapsulated volume can also be “walls”as used herein.

As used herein, “mined” refers to a material which has been removed ordisturbed from an original stratographic or geological location to asecond and different location. Typically, mined material can be producedby rubbilizing, crushing, explosively detonating, or otherwise removingmaterial from a geologic formation.

As used herein, “substantially stationary” refers to nearly stationarypositioning of materials with a degree of allowance for subsidence,expansion due to the popcorn effect, and/or settling as hydrocarbons areremoved from the hydrocarbonaceous material. In contrast, anycirculation and/or flow of hydrocarbonaceous material such as that foundin fluidized beds or rotating retorts involves highly substantialmovement and handling of hydrocarbonaceous material.

As used herein, “substantial” when used in reference to a quantity oramount of a material, or a specific characteristic thereof, refers to anamount that is sufficient to provide an effect that the material orcharacteristic was intended to provide. The exact degree of deviationallowable may in some cases depend on the specific context. Similarly,“substantially free of” or the like refers to the lack of an identifiedelement or agent in a composition. Particularly, elements that areidentified as being “substantially free of” are either completely absentfrom the composition, or are included only in amounts which are smallenough so as to have no measurable effect on the composition.

As used herein, “about” refers to a degree of deviation based onexperimental error typical for the particular property identified. Thelatitude provided the term “about” will depend on the specific contextand particular property and can be readily discerned by those skilled inthe art. The term “about” is not intended to either expand or limit thedegree of equivalents which may otherwise be afforded a particularvalue. Further, unless otherwise stated, the term “about” shallexpressly include “exactly,” consistent with the discussion belowregarding ranges and numerical data.

Concentrations, dimensions, amounts, and other numerical data may bepresented herein in a range format. It is to be understood that suchrange format is used merely for convenience and brevity and should beinterpreted flexibly to include not only the numerical values explicitlyrecited as the limits of the range, but also to include all theindividual numerical values or sub-ranges encompassed within that rangeas if each numerical value and sub-range is explicitly recited. Forexample, a range of about 1 to about 200 should be interpreted toinclude not only the explicitly recited limits of 1 and about 200, butalso to include individual sizes such as 2, 3, 4, and sub-ranges such as10 to 50, 20 to 100, etc.

As used herein, a plurality of items, structural elements, compositionalelements, and/or materials may be presented in a common list forconvenience. However, these lists should be construed as though eachmember of the list is individually identified as a separate and uniquemember. Thus, no individual member of such list should be construed as ade facto equivalent of any other member of the same list solely based ontheir presentation in a common group without indications to thecontrary.

Embodiments of the Invention

In accordance with the present invention, a method of recoveringhydrocarbons from hydrocarbonaceous materials can include forming aconstructed permeability control infrastructure. This constructedinfrastructure defines a substantially encapsulated volume. A mined orharvested hydrocarbonaceous material can be introduced into the controlinfrastructure to form a permeable body of hydrocarbonaceous material.The permeable body can be heated sufficient to remove hydrocarbonstherefrom. During heating, the hydrocarbonaceous material issubstantially stationary as the constructed infrastructure is a fixedstructure. Removed hydrocarbons can be collected for further processing,use in the process, and/or use as recovered.

Each of these aspects of the present invention is described in furtherdetail below. The constructed permeability control infrastructure can beformed using existing grade as floor support and/or as side wall supportfor the constructed infrastructure. For example, the controlinfrastructure can be formed as a free standing structure, i.e. usingonly existing grade as a floor with side walls being man-made.Alternatively, the control infrastructure can be formed within anexcavated pit. Regardless, the control infrastructures of the presentinvention are always formed above-grade.

A constructed permeability control infrastructure of the presentinvention can include a permeability control impoundment which defines asubstantially encapsulated volume. The permeability control impoundmentof the present invention is substantially free of undisturbed geologicalformations. Specifically, the permeability control aspect of theimpoundment can be completely constructed and manmade as a separateisolation mechanism for prevention of uncontrolled migration of materialinto or out of the encapsulated volume.

In one embodiment of the present invention, the permeability controlimpoundment can be formed along walls of an excavated hydrocarbonaceousmaterial deposit. For example, oil shale, tar sands, or coal can bemined from a deposit to form a cavity which corresponds approximately toa desired encapsulation volume for an impoundment. The excavated cavitycan then be used as a form and support to create the permeabilitycontrol impoundment.

In one alternative aspect of the present invention, at least oneadditional excavated hydrocarbonaceous material deposit can be formedsuch that a plurality of impoundments can be operated. Further, such aconfiguration can facilitate a reduction in transportation distance ofthe mined material. Specifically, the mined hydrocarbonaceous materialfor any particular encapsulated volume can be mined from an adjacentexcavated hydrocarbonaceous material deposit. In this manner, a grid ofconstructed structures can be built such that mined material can beimmediately and directly filled into an adjacent impoundment.

Mining and/or excavation of hydrocarbonaceous deposits can beaccomplished using any suitable technique. Conventional surface miningcan be used, although alternative excavators can also be used withoutrequirement of transportation of the mined materials. In one specificembodiment, the hydrocarbonaceous deposit can be excavated using acrane-suspended excavator. One example of a suitable excavator caninclude vertical tunnel boring machines. Such machines can be configuredto excavate rock and material beneath the excavator. As material isremoved, the excavator is lowered to ensure substantially continuouscontact with a formation. Removed material can be conveyed out of theexcavation area using conveyors or lifts. Alternatively, the excavationcan occur under aqueous slurry conditions to reduce dust problems andact as a lubricant/coolant. The slurry material can be pumped out of theexcavation for separation of solids in a settling tank or other similarsolid-liquid separator, or the solids may be allowed to precipitatedirectly in an impoundment. This approach can be readily integrated withsimultaneous or sequential solution-based recovery of metals and othermaterials as described in more detail below.

Further, excavation and formation of a permeability control impoundmentcan be accomplished simultaneously. For example, an excavator can beconfigured to remove hydrocarbonaceous material while side walls of animpoundment are formed. Material can be removed from just underneathedges of the side walls such that the walls can be guided downward toallow additional wall segments to be stacked above. This approach canallow for increased depths while avoiding or reducing dangers of cave-inprior to formation of supporting impoundment walls.

The impoundment can be formed of any suitable material which providesisolation of material transfer across walls of the impoundment. In thismanner, integrity of the walls is retained during operation of thecontrol infrastructure sufficient to substantially prevent uncontrolledmigration of fluids outside of the control infrastructure. Non-limitingexamples of suitable material for use in forming the impoundment of theconstructed permeability control infrastructure can include clay,bentonite clay (e.g. clay comprising at least a portion of bentonite),compacted fill, refractory cement, cement, synthetic geogrids,fiberglass, rebar, nanocarbon fullerene additives, filled geotextilebags, polymeric resins, oil resistant PVC liners, or combinationsthereof. Engineered cementitious composites (ECC) materials, fiberreinforced composites, and the like can be particularly strong and canbe readily engineered to meet permeability and temperature tolerancerequirements of a given installation. As a general guideline, materialshaving low permeability and high mechanical integrity at operatingtemperatures of the infrastructure are preferred although not required.For example, materials having a melting point above the maximumoperating temperature of the infrastructure can be useful to maintaincontainment during and after heating and recovery. However, lowertemperature materials can also be used if a non-heated buffer zone ismaintained between the walls and heated portions of the permeable body.Such buffer zones can range from 6 inches to 50 feet depending on theparticular material used for the impoundment and the composition of thepermeable body. In another aspect of the present invention, walls of theimpoundment can be acid, water and/or brine resistant, e.g. sufficientto withstand exposure to solvent recovery and/or rinsing with acidic orbrine solutions, as well as to steam or water. For impoundment wallsformed along formations or other solid support, the impoundment wallscan be formed of a sprayed grouting, sprayed liquid emulsions, or othersprayed material such as sprayable refractory grade grouting which formsa seal against the formation and creates the permeability control wallof the impoundments of the present invention. Impoundment walls may besubstantially continuous such that the impoundment defines theencapsulated volume sufficiently to prevent substantial movement offluids into or out of the impoundment other than defined inlets andoutlets, e.g. via conduits or the like as discussed herein. In thismanner, the impoundments of the present invention can readily meetgovernment fluid migration regulations. Alternatively, or in combinationwith a manufactured barrier, portions of the impoundment walls can beundisturbed geological formation and/or compacted earth. In such cases,the constructed permeability control infrastructure is a combination ofpermeable and impermeable walls as described in more detail below.

In one detailed aspect of the present invention, a portion ofhydrocarbonaceous material, either pre- or post-processed, can be usedas a cement fortification and/or cement base which are then poured inplace to form portions or the entirety of walls of the controlinfrastructure. These materials can be formed in place or can bepreformed and then assembled on site to form an integral impoundmentstructure. For example, the impoundment can be constructed by castforming in place as a monolithic body, extrusion, stacking of preformedor precast pieces, concrete panels joined by a grout (cement, ECC orother suitable material), inflated form, or the like. The forms can bebuilt up against a formation or can be stand alone structures. Forms canbe constructed of any suitable material such as, but not limited to,steel, wood, fiberglass, polymer, or the like. The forms can beassembled in place or may be oriented using a crane or other suitablemechanism. Alternatively, the constructed permeability controlinfrastructure can be formed of gabions and/or geosynthetic fabricsassembled in layers with compacted fill material. Optional binders canbe added to enhance compaction of the permeability control walls. In yetanother detailed aspect of the present invention, the controlinfrastructure can comprise, or consists essentially of, sealant, grout,rebar, synthetic clay, bentonite clay, clay lining, refractory cement,high temperature geomembranes, drain pipes, alloy sheets, orcombinations thereof.

In one embodiment, the construction of impoundment walls and floors caninclude multiple compacted layers of indigenous or manipulated low gradeshale with any combination of sand, cement, fiber, plant fiber, nanocarbons, crushed glass, reinforcement steel, engineered carbonreinforcement grid, calcium, and the like. In addition to such compositewalls, designs which inhibit long term fluid and gas migration throughadditional impermeability engineering can be employed including, but notlimited to, liners, geo-membranes, compacted soils, imported sand,gravel or rock and gravity drainage contours to move fluids and gasesaway from impervious layers to egress exits. Impoundment floor and wallconstruction, can, but need not comprise, a stepped up or stepped downslope or bench as the case of mining course may dictate following theoptimal ore grade mining. In any such stepped up or down applications,floor leveling and containment wall construction can typically drain orslope to one side or to a specific central gathering area(s) for removalof fluids by gravity drainage assistance.

Optionally, capsule wall and floor construction can include insulationwhich prevents heat transfer outside of the constructed infrastructureor outside of inner capsules or conduits within the primary constructedcapsule containment. Insulation can comprise manufactured materials,cement or various materials other materials which are less thermallyconductive than surrounding masses, i.e. permeable body, formation,adjacent infrastructures, etc. Thermally insulating barriers can also beformed within the permeable body, along impoundment walls, ceilingsand/or floors. One detailed aspect of the present invention includes theuse of biodegradable insulating materials, e.g. soy insulation and thelike. This is consistent with embodiments of the present inventionwherein the impoundment is a single use system such that insulations,pipes, and/or other components can have a relatively low useful life,e.g. less than 1-2 years. This can reduce equipment costs as well asreduce long-term environmental impact.

The structures and methods of the present invention can be applied atalmost any scale. Larger encapsulated volumes and increased numbers ofimpoundments can readily produce hydrocarbon products and performancecomparable to or exceeding smaller constructed infrastructures. As anillustration, single impoundments can range in size from tens of metersacross to tens of acres. Optimal impoundment sizes may vary depending onthe hydrocarbonaceous material and operating parameters, however it isexpected that suitable areas can range from about one-half to five acresin top plan surface area.

The methods and infrastructures of the present invention can be used forrecovery of hydrocarbons from a variety of hydrocarbonaceous materials.One particular advantage of the present invention is a wide degree oflatitude in controlling particle size, conditions, and composition ofthe permeable body introduced into the encapsulated volume. Non-limitingexamples of mined hydrocarbonaceous material which can be treatedcomprise oil shale, tar sands, coal, lignite, bitumen, peat, orcombinations thereof. In some cases it can be desirable to provide asingle type of hydrocarbonaceous material so that the permeable bodyconsists essentially of one of the above materials. However, thepermeable body can include mixtures of these materials such that grade,oil content, hydrogen content, permeability and the like can be adjustedto achieve a desired result. Further, different hydrocarbon materialscan be placed in multiple layers or in a mixed fashion such as combiningcoal, oil shale, tar sands, biomass, and/or peat.

In one embodiment, hydrocarbon containing material can be classifiedinto various inner capsules within a primary constructed infrastructurefor optimization reasons. For instance, layers and depths of mined oilshale formations may be richer in certain depth pay zones as they aremined. Once, blasted, mined, shoveled and hauled inside of capsule forplacement, richer oil bearing ores can be classified or mixed byrichness for optimal yields, faster recovery, or for optimal averagingwithin each impoundment. Further, providing layers of differingcomposition can have added benefits. For example, a lower layer of tarsands can be oriented below an upper layer of oil shale. Generally, theupper and lower layers can be in direct contact with one anotheralthough this is not required. The upper layer can include heating pipesembedded therein as described in more detail below. The heating pipescan heat the oil shale sufficient to liberate kerogen oil, includingshort-chain liquid hydrocarbons, which can act as a solvent for bitumenremoval from the tar sands. In this manner, the upper layer acts as anin situ solvent source for enhancing bitumen removal from the lowerlayer. Heating pipes within the lower layer are optional such that thelower layer can be free of heating pipes or may include heating pipes,depending on the amount of heat transferred via downward passing liquidsfrom the upper layer and any other heat sources. The ability toselectively control the characteristics and composition of the permeablebody adds a significant amount of freedom in optimizing oil yields andquality.

Furthermore, in many embodiments of the present invention, the liberatedgaseous and liquid products act as an in situ produced solvent whichsupplements kerogen removal and/or additional hydrocarbon removal fromthe hydrocarbonaceous material.

In yet another detailed aspect of the present invention, the permeablebody can further comprise an additive or biomass. Additives can includeany composition which acts to increase the quality of removedhydrocarbons, e.g. increased API, decreased viscosity, improved flowproperties, reduced wetting of residual shale, reduction of sulfur,hydrogenation agents, etc. Non-limiting examples of suitable additivescan include bitumen, kerogen, propane, natural gas, natural gascondensate, crude oil, refining bottoms, asphaltenes, common solvents,other diluents, and combinations of these materials. In one specificembodiment, the additive can include a flow improvement agent and/or ahydrogen donor agent. Some materials can act as both or either agents toimprove flow or as a hydrogen donor. Non-limiting examples of suchadditives can include methane, natural gas condensates, common solventsuch as acetone, toluene, benzene, etc., and other additives listedabove. Additives can act to increase the hydrogen to carbon ratio in anyhydrocarbon products, as well as act as a flow enhancement agent. Forexample, various solvents and other additives can create a physicalmixture which has a reduced viscosity and/or reduced affinity forparticulate solids, rock and the like. Further, some additives canchemically react with hydrocarbons and/or allow liquid flow of thehydrocarbon products. Any additives used can become part of a finalrecovered product or can be removed and reused or otherwise disposed of.

Similarly, biological hydroxylation of hydrocarbonaceous materials toform synthetic gas or other lighter weight products can be accomplishedusing known additives and approaches. Other enzymes or biocatalysts canalso be used in a similar manner. Further, manmade materials can also beused as additives such as, but not limited to, tires, polymeric refuse,or other hydrocarbon-containing materials.

Although the methods of the present invention are broadly applicable, asa general guideline, the permeable body can include particles from about⅛ inch to about 6 feet, and in some cases less than 1 foot and in othercases less than about 6 inches. However, as a practical matter, sizesfrom about 2 inches to about 2 feet can provide good results with about1 foot diameter being useful for oil shale especially. Void space can bean important factor in determining optimal particle diameters. As ageneral matter, any functional void space can be used; however, about15% to about 40% and in some cases about 30% usually provides a goodbalance of permeability and effective use of available volumes. Voidvolumes can be varied somewhat by varying other parameters such asheating conduit placement, additives, and the like. Mechanicalseparation of mined hydrocarbonaceous materials allows creation of finemesh, high permeability particles which enhance thermal dispersion ratesonce placed in capsule within the impoundment. The added permeabilityallows for more reasonable, low temperatures which also help to avoidhigher temperatures which result in greater CO₂ production fromcarbonate decomposition and associated release of trace heavy metals,volatile organics, and other compounds which can create toxic effluentand/or undesirable materials which must be monitored and controlled.

In one embodiment, computer assisted mining, mine planning, hauling,blasting, assay, loading, transport, placement, and dust controlmeasures can be utilized to fill and optimize the speed of minedmaterial movement into the constructed capsule containment structure. Inone alternative aspect of the present invention, the impoundments of thepresent invention can be formed in excavated volumes of ahydrocarbonaceous formation, although other locations remote from thecontrol infrastructure can also be useful. For example, somehydrocarbonaceous formations have relatively thin hydrocarbon-richlayers, e.g. less than about 300 feet. Therefore, vertical mining anddrilling tend to not be cost effective. In such cases, horizontal miningcan be useful to recover the hydrocarbonaceous materials for formationof the permeable body. Although horizontal mining continues to be achallenging endeavor, a number of technologies have been developed andcontinue to be developed which can be useful in connection with thepresent invention. In such cases, at least a portion of the impoundmentcan be formed across a horizontal layer, while other portions of theimpoundment can be formed along and/or adjacent non-hydrocarbon bearingformation layers. Other mining approaches such as, but not limited to,room and pillar mining can provide an effective source ofhydrocarbonaceous material with minimal waste and/or reclamation whichcan be transported to an impoundment and treated in accordance with thepresent invention.

As mentioned herein, the present invention allows for a large degree ofcontrol regarding properties and characteristics of the permeable bodywhich can be designed and optimized for a given installation.Impoundments, individually and across a plurality of impoundments can bereadily tailored and classified based on varying composition ofmaterials, intended products and the like. For example, severalimpoundments can be dedicated to production of heavy crude oil, whileothers can be configured for production of lighter products and/or syngas. Non-limiting example of potential classifications and factors caninclude catalyst activity, enzymatic reaction for specific products,aromatic compounds, hydrogen content, microorganism strain or purpose,upgrading process, target final product, pressure (effects productquality and type), temperature, swelling behavior, aquathermalreactions, hydrogen donor agents, heat superdisposition, garbageimpoundment, sewage impoundment, reusable pipes, and others. Typically,a plurality of these factors can be used to configure impoundments in agiven project area for distinct products and purposes.

The comminuted hydrocarbonaceous material can be filled into the controlinfrastructure to form the permeable body in any suitable manner.Typically the comminuted hydrocarbonaceous material can be conveyed intothe control infrastructure by dumping, conveyors or other suitableapproaches. As mentioned previously, the permeable body can have asuitably high void volume. Indiscriminate dumping can result inexcessive compaction and reduction of void volumes. Thus, the permeablebody can be formed by low compaction conveying of the hydrocarbonaceousmaterial into the infrastructure. For example, retracting conveyors canbe used to deliver the material near a top surface of the permeable bodyas it is formed. In this way, the hydrocarbonaceous material can retaina significant void volume between particles without substantial furthercrushing or compaction despite some small degree of compaction whichoften results from lithostatic pressure as the permeable body is formed.

Once a desired permeable body has been formed within the controlinfrastructure, heat can be introduced sufficient to begin removal ofhydrocarbons, e.g. via pyrolysis. A suitable heat source can bethermally associated with the permeable body. Optimal operatingtemperatures within the permeable body can vary depending on thecomposition and desired products. However, as a general guideline,operating temperatures can range from about 200° F. to about 750° F.Temperature variations throughout the encapsulated volume can vary andmay reach as high as 900° F. or more in some areas. In one embodiment,the operating temperature can be a relatively lower temperature tofacilitate production of liquid product such as from about 200° F. toabout 650° F. This heating step can be a roasting operation whichresults in beneficiation of the crushed ore of the permeable body.Further, one embodiment of the present invention comprises controllingthe temperature, pressure and other variables sufficient to producepredominantly, and in some cases substantially only, liquid product.Generally, products can include both liquid and gaseous products, whileliquid products can require fewer processing steps such as scrubbersetc. The relatively high permeability of the permeable body allows forproduction of liquid hydrocarbon products and minimization of gaseousproducts, depending to some extent on the particular starting materialsand operating conditions. In one embodiment, the recovery of hydrocarbonproducts can occur substantially in the absence of cracking within thepermeable body.

In one aspect of the present invention, heat can be transferred to thepermeable body via convection. Heated gases can be injected into thecontrol infrastructure such that the permeable body is primarily heatedvia convection as the heated gases pass throughout the permeable body.Heated gases can be produced by combustion of natural gas, hydrocarbonproduct, or any other suitable source. The heated gases can be importedfrom external sources or recovered from the process of the presentinvention.

Alternatively, or in combination with convective heating, a highlyconfigurable approach can include embedding a plurality of conduitswithin the permeable body. The conduits can be configured for use asheating pipes, cooling pipes, heat transfer pipes, drainage pipes, orgas pipes. Further, the conduits can be dedicated to a single functionor may serve multiple functions during operation of the infrastructure,i.e. heat transfer and drainage. The conduits can be formed of anysuitable material, depending on the intended function. Non-limitingexamples of suitable materials can include clay pipes, refractory cementpipes, refractory ECC pipes, poured in place pipes, metal pipes such ascast iron, stainless steel etc., polymer such as PVC, and the like. Inone specific embodiment, all or at least a portion of the embeddedconduits can comprise a degradable material. For example, non-galvanized6″ cast iron pipes can be effectively used for single use embodimentsand perform well over the useful life of the impoundment, typically lessthan about 2 years. Further, different portions of the plurality ofconduits can be formed of different materials. Poured in place pipes canbe especially useful for very large encapsulation volumes where pipediameters exceed several feet. Such pipes can be formed using flexiblewraps which retain a viscous fluid in an annular shape. For example, PVCpipes can be used as a portion of a form along with flexible wraps,where concrete or other viscous fluid is pumped into an annular spacebetween the PVC and flexible wrap. Depending on the intended function,perforations or other apertures can be made in the conduits to allowfluids to flow between the conduits and the permeable body. Typicaloperating temperatures exceed the melting point of conventional polymerand resin pipes. In some embodiments, the conduits can be placed andoriented such that the conduits intentionally melt or otherwise degradeduring operation of the infrastructure.

The plurality of conduits can be readily oriented in any configuration,whether substantially horizontal, vertical, slanted, branched, or thelike. At least a portion of the conduits can be oriented alongpredetermined pathways prior to embedding the conduits within thepermeable body. The predetermined pathways can be designed to improveheat transfer, gas-liquid-solid contacting, maximize fluid delivery orremoval from specific regions within the encapsulated volume, or thelike. Further, at least a portion the conduits can be dedicated toheating of the permeable body. These heating conduits can be selectivelyperforated to allow heated gases or other fluids to convectively heatand mix throughout the permeable body. The perforations can be locatedand sized to optimize even and/or controlled heating throughout thepermeable body. Alternatively, the heating conduits can form a closedloop such that heating gases or fluids are segregated from the permeablebody. Thus, a “closed loop” does not necessarily require recirculation,rather isolation of heating fluid from the permeable body. In thismanner, heating can be accomplished primarily or substantially onlythrough thermal conduction across the conduit walls from the heatingfluids into the permeable body. Heating in a closed loop allows forprevention of mass transfer between the heating fluid and permeable bodyand can reduce formation and/or extraction of gaseous hydrocarbonproducts.

During the heating or roasting of the permeable body, localized areas ofheat which exceed parent rock decomposition temperatures, often aboveabout 900° F., can reduce yields and form carbon dioxide and undesirablecontaminating compounds which can lead to leachates containing heavymetals, soluble organics and the like. The heating conduits of thepresent invention can allow for substantial elimination of suchlocalized hot spots while maintaining a vast majority of the permeablebody within a desired temperature range. The degree of uniformity intemperature can be a balance of cost (e.g. for additional heatingconduits) versus yields. However, at least about 85% of the permeablebody can readily be maintained within about 5-10% of a targettemperature range with substantially no hot spots, i.e. exceeding thedecomposition temperature of the hydrocarbonaceous materials such asabout 800° F. and in many cases about 900° F. Thus, operated asdescribed herein, the systems of the present invention can allow forrecovery of hydrocarbons while eliminating or substantially avoidingproduction of undesirable leachates. Although products can varyconsiderably depending on the starting materials, high quality liquidand gaseous products are possible. In accordance with one embodiment ofthe present invention, a crushed oil shale material can produce a liquidproduct having an API from about 30 to about 45, with about 33 to about38 being currently typical, directly from the oil shale withoutadditional treatment. Interestingly, practice of the present inventionhas led to an understanding that pressure appears to be a much lessinfluential factor on the quality of recovered hydrocarbons thantemperature and heating times. Although heating times can varyconsiderably, depending on void space, permeable body composition,quality, etc., as a general guideline times can range from a few days(i.e. 3-4 days) up to about one year. In one specific example, heatingtimes can range from about 2 weeks to about 4 months. Under-heating oilshale at short residence times, i.e. minutes to several hours, can leadto formation of leachable and/or somewhat volatile hydrocarbons.Accordingly, the present invention allows for extended residence timesat moderate temperatures such that organics present in oil shale can bevolatilized and/or carbonized, leaving insubstantial leachable organics.In addition, the underlying shale is not generally decomposed or alteredwhich reduces soluble salt formation.

Further, conduits can be oriented among a plurality of impoundmentsand/or control infrastructures to transfer fluids and/or heat betweenthe structures. The conduits can be welded to one another usingconventional welding or the like. Further, the conduits can includejunctions which allow for rotation and or small amounts of movementduring expansion and subsidence of material in the permeable body.Additionally, the conduits can include a support system which acts tosupport the assembly of conduits prior to and during filling of theencapsulated volume, as well as during operation. For example, duringheating flows of fluids, heating and the like can cause expansion(fracturing or popcorn effect) or subsidence sufficient to createpotentially damaging stress and strain on the conduits and associatedjunctions. A truss support system or other similar anchoring members canbe useful in reducing damage to the conduits. The anchoring members caninclude cement blocks, I-beams, rebar, columns, etc. which can beassociated with walls of the impoundment, including side walls, floorsand ceilings.

Alternatively, the conduits can be completely constructed and assembledprior to introduction of any mined materials into the encapsulatedvolume. Care and planning can be considered in designing thepredetermined pathways of the conduits and method of filling the volumein order to prevent damage to the conduits during the filling process asthe conduits are buried. Thus, as a general rule, the conduits used inthe present invention are oriented ab initio, or prior to embedding inthe permeable body such that they are non-drilled. As a result,construction of the conduits and placement thereof can be performedwithout extensive core drilling and/or complicated machinery associatedwith well-bore or horizontal drilling. Rather, horizontal or any otherorientation of conduit can be readily achieved by assembling the desiredpredetermined pathways prior to, or contemporaneous with, filling theinfrastructure with the mined hydrocarbonaceous material. Thenon-drilled, hand/crane-placed conduits oriented in various geometricpatterns can be laid with valve controlled connecting points which yieldprecise and closely monitored heating within the capsule impoundment.The ability to place and layer conduits including connecting, bypass andflow valves, and direct injection and exit points, allow for precisiontemperature and heating rates, precision pressure and pressurizationrates, and precision fluid and gas ingress, egress and compositionadmixtures. For example, when a bacteria, enzyme, or other biologicalmaterial is used, optimal temperatures can be readily maintainedthroughout the permeable body to increase performance, reaction, andreliability of such biomaterials.

The conduits will generally pass through walls of the constructedinfrastructure at various points. Due to temperature differences andtolerances, it can be beneficial to include an insulating material atthe interface between the wall and the conduits. The dimensions of thisinterface can be minimized while also allowing space for thermalexpansion differences during startup, steady-state operation,fluctuating operating conditions, and shutdown of the infrastructure.The interface can also involve insulating materials and sealant deviceswhich prevent uncontrolled egress of hydrocarbons or other materialsfrom the control infrastructure. Non-limiting examples of suitablematerials can include high temperature gaskets, metal alloys, ceramics,clay or mineral liners, composites or other materials which havingmelting points above typical operating temperatures and act as acontinuation of the permeability control provided by walls of thecontrol infrastructure.

Further, walls of the constructed infrastructure can be configured tominimize heat loss. In one aspect, the walls can be constructed having asubstantially uniform thickness which is optimized to provide sufficientmechanical strength while also minimizing the volume of wall materialthrough which the conduits pass. Specifically, excessively thick wallscan reduce the amount of heat which is transferred into the permeablebody by absorbing the same through conduction. Conversely, the walls canalso act as a thermal barrier to somewhat insulate the permeable bodyand retain heat therein during operation.

In one embodiment, fluid and gas compounds within the permeable body canbe altered for desired extractive products using, as an example, inducedpressure through gases or piled lithostatic pressure from piled rubble.Thus, some degree of upgrading and/or modification can be accomplishedsimultaneous with the recovery process of the present invention.Further, certain hydrocarbonaceous materials can require treatment usingspecific diluents or other materials. For example, treatment of tarsands can be readily accomplished by steam injection or solventinjection to facilitate separation of bitumen from sand particlesaccording to well known mechanisms.

With the above description in mind, FIG. 1 depicts a side view of oneembodiment of the invention showing an engineered capsule containmentand extraction impoundment 100 where existing grade 108 is usedprimarily as support for the impermeable floor layer 112. Exteriorcapsule impoundment side walls 102 provide containment and can, but neednot be, subdivided by interior walls 104. Subdividing can createseparate containment capsules 122 within a greater capsule containmentof the impoundment 100 which can be any geometry, size or subdivision.Further subdivisions can be horizontally or vertically stacked. Bycreating separate containment capsules 122 or chambers, classificationof lower grade materials, varied gases, varied liquids, varied processstages, varied enzymes or microbiology types, or other desired andstaged processes can be readily accommodated. Sectioned capsulesconstructed as silos within larger constructed capsules can also bedesigned to provide staged and sequenced processing, temperatures, gasand fluid compositions and thermal transfers. Such sectioned capsulescan provide additional environmental monitoring and can be built oflined and engineered tailings berms similar to the primary exteriorwalls. In one embodiment, sections within the impoundment 100 can beused to place materials in isolation, in the absence of external heat,or with the intent of limited or controlled combustion or solventapplication. Lower content hydrocarbon bearing material can be useful asa combustion material or as fill or a berm wall building material.Material which does not meet a various cut-off grade thresholds can alsobe sequestered without alteration in an impoundment dedicated for suchpurpose. In such embodiments, such areas may be completely isolated orbypassed by heat, solvents, gases, liquids, or the like. Optionalmonitoring devices and/or equipment can be permanently or temporarilyinstalled within the impoundment or outside perimeters of theimpoundments in order to verify containment of the sequestered material.

Walls 102 and 104 as well as cap 116 and impermeable layer 112 can beengineered and reinforced by gabions 146 and or geogrid 148 layered infill compaction. Alternatively, these walls 102, 104, 116 and 112 whichcomprise the permeability control impoundment and collectively definethe encapsulated volume can be formed of any other suitable material aspreviously described. In this embodiment, the impoundment 100 includesside walls 102 and 104 which are self-supporting. In one embodiment,tailings berms, walls, and floors can be compacted and engineered forstructure as well as permeability. The use of compacted geogrids andother deadman structures for support of berms and embankments can beincluded prior to or incorporated with permeability control layers whichmay include sand, clay, bentonite clay, gravel, cement, grout,reinforced cement, refractory cements, insulations, geo-membranes,drainpipes, temperature resistant insulations of penetrating heatedpipes, etc.

In one alternative embodiment, the permeability control impoundment caninclude side walls which are compacted earth and/or undisturbedgeological formations while the cap and floors are impermeable.Specifically, in such embodiments an impermeable cap can be used toprevent uncontrolled escape of volatiles and gases from the impoundmentsuch that appropriate gas collection outlets can be used. Similarly, animpermeable floor can be used to contain and direct collected liquids toa suitable outlet such the drain system 133 to remove liquid productsfrom lower regions of the impoundment. Although impermeable side wallscan be desirable in some embodiments, such are not always required. Insome cases, side walls can be exposed undisturbed earth or compactedfill or earth, or other permeable material. Having permeable side wallsmay allow some small egress of gases and/or liquids from theimpoundment.

Above, below, around and adjacent to constructed capsule containmentvessels environmental hydrology measures can be engineered to redirectsurface water away from the capsule walls, floors, caps, etc. duringoperation. Further, gravity assisted drainage pipes and mechanisms canbe utilized to aggregate and channel fluids, liquids or solvents withinthe encapsulated volume to central gathering, pumping, condensing,heating, staging and discharge pipes, silos, tanks, and/or wells asneeded. In a similar manner, steam and/or water which is intentionallyintroduce, e.g. for tar sands bitumen treatment, can be recycled.

Once wall structures 102 and 104 have been constructed above aconstructed and impermeable floor layer 112 which commences from groundsurface 106, the mined rubble 120 (which may be crushed or classifiedaccording to size or hydrocarbon richness), can be placed in layers upon(or next to) placed tubular heating pipes 118, fluid drainage pipes 124,and, or gas gathering or injection pipes 126. These pipes can beoriented and designed in any optimal flow pattern, angle, length, size,volume, intersection, grid, wall sizing, alloy construction, perforationdesign, injection rate, and extraction rate. In some cases, pipes suchas those used for heat transfer can be connected to, recycled through orderive heat from heat source 134. Alternatively, or in combination with,recovered gases can be condensed by a condenser 140. Heat recovered bythe condenser can be optionally used to supplement heating of thepermeable body or for other process needs.

Heat source 134 can derive, amplify, gather, create, combine, separate,transmit or include heat derived from any suitable heat sourceincluding, but not limited to, fuel cells, solid oxide fuel cells, solarsources, wind sources, hydrocarbon liquid or gas combustion heaters,geothermal heat sources, nuclear power plant, coal fired power plant,radio frequency generated heat, wave energy, flameless combustors,natural distributed combustors, or any combination thereof. In somecases, electrical resistive heaters or other heaters can be used,although solid oxide fuel cells and combustion-based heaters arecurrently preferred. In some locations, geothermal water can becirculated to the surface in adequate amounts to heat the permeable bodyand directed into the infrastructure.

In another embodiment, electrically conductive material can bedistributed throughout the permeable body and an electric current can bepassed through the conductive material sufficient to generate heat. Theelectrically conductive material can include, but is not limited to,metal pieces or beads, conductive cement, metal coated particles,metal-ceramic composites, conductive semi-metal carbides, calcinedpetroleum coke, laid wire, combinations of these materials, and thelike. The electrically conductive material can be premixed havingvarious mesh sizes or the materials can be introduced into the permeablebody subsequent to formation of the permeable body.

Liquids or gases can transfer heat from heat source 134, or in anotherembodiment, in the cases of hydrocarbon liquid or gas combustion, radiofrequency generators (microwaves), fuel cells, or solid oxide fuel cellsall can, but need not, actually generate heat inside of capsuleimpoundment area 114 or 122. In one embodiment, heating of the permeablebody can be accomplished by convective heating from hydrocarboncombustion. Of particular interest is hydrocarbon combustion performedunder stoichiometric conditions of fuel to oxygen. Stoichiometricconditions can allow for significantly increased heat gas temperatures.Stoichiometric combustion can employ but does not generally require apure oxygen source which can be provided by known technologiesincluding, but not limited to, oxygen concentrators, membranes,electrolysis, and the like. In some embodiments oxygen can be providedfrom air with stoichiometric amounts of oxygen and hydrogen. Combustionoff gas can be directed to an ultra-high temperature heat exchanger,e.g. a ceramic or other suitable material having an operatingtemperature above about 2500° F. Air obtained from ambient or recycledfrom other processes can be heated via the ultra high temperature heatexchanger and then sent to the impoundment for heating of the permeablebody. The combustion off gases can then be sequestered without the needfor further separation, i.e. because the off gas is predominantly carbondioxide and water.

In order to minimize heat losses, distances can be minimized between thecombustion chamber, heat exchanger and impoundments. Therefore, in onespecific detailed embodiment portable combustors can be attached toindividual heating conduits or smaller sections of conduits. Portablecombustors or burners can individually provide from about 100,000 Btu toabout 1,000,000 Btu with about 600,000 Btu per pipe generally beingsufficient.

Alternatively, in-capsule combustion can be initiated inside of isolatedcapsules within a primary constructed capsule containment structure.This process partially combusts hydrocarbonaceous material to provideheat and intrinsic pyrolysis. Unwanted air emissions 144 can be capturedand sequestered in a formation 108 once derived from capsule containment114, 122 or from heat source 134 and delivered by a drilled well bore142. Heat source 134 can also create electricity and transmit, transformor power via electrical transmission lines 150. The liquids or gasesextracted from capsule impoundment treatment area 114 or 122 can bestored in a nearby holding tank 136 or within a capsule containment 114or 122. For example, the impermeable floor layer 112 can include asloped area 110 which directs liquids towards drain system 133 whereliquids are directed to the holding tank.

As rubble material 120 is placed with piping 118, 124, 126, and 128,various measurement devices or sensors 130 are envisioned to monitortemperature, pressure, fluids, gases, compositions, heating rates,density, and all other process attributes during the extractive processwithin, around, or underneath the engineered capsule containmentimpoundment 100. Such monitoring devices and sensors 130 can bedistributed anywhere within, around, part of, connected to, or on top ofplaced piping 118, 124, 126, and 128 or, on top of, covered by, orburied within rubble material 120 or impermeable barrier zone 112.

As placed rubble material 120 fills the capsule treatment area 114 or122, 120 becomes the ceiling support for engineered impermeable capbarrier zone 138, and wall barrier construction 170, which may includeany combination of impermeability and engineered fluid and gas barrieror constructed capsule construction comprising those which may make up112 including, but not limited to clay 162, compacted fill or importmaterial 164, cement or refractory cement containing material 166, geosynthetic membrane, liner or insulation 168. Above 138, fill material116 is placed to create lithostatic pressure upon the capsule treatmentareas 114 or 122. Covering the permeable body with compacted fillsufficient to create an increased lithostatic pressure within thepermeable body can be useful in further increasing hydrocarbon productquality. A compacted fill ceiling can substantially cover the permeablebody, while the permeable body in return can substantially support thecompacted fill ceiling. The compacted fill ceiling can further besufficiently impermeable to removed hydrocarbon or an additional layerof permeability control material can be added in a similar manner asside and/or floor walls. Additional pressure can be introduced intoextraction capsule treatment area 114 or 122 by increasing any gas orfluid once extracted, treated or recycled, as the case may be, via anyof piping 118, 124, 126, or 128. All relative measurements, optimizationrates, injection rates, extraction rates, temperatures, heating rates,flow rates, pressure rates, capacity indicators, chemical compositions,or other data relative to the process of heating, extraction,stabilization, sequestration, impoundment, upgrading, refining orstructure analysis within the capsule impoundment 100 are envisionedthrough connection to a computing device 132 which operates computersoftware for the management, calculation and optimization of the entireprocess. Further, core drilling, geological reserve analysis and assaymodeling of a formation prior to blasting, mining and hauling (or atanytime before, after or during such tasks) can serve as data inputfeeds into computer controlled mechanisms that operate software toidentify optimal placements, dimensions, volumes and designs calibratedand cross referenced to desired production rate, pressure, temperature,heat input rates, gas weight percentages, gas injection compositions,heat capacity, permeability, porosity, chemical and mineral composition,compaction, density. Such analysis and determinations may include otherfactors like weather data factors such as temperature and air moisturecontent impacting the overall performance of the constructedinfrastructure. Other data such as ore moisture content, hydrocarbonrichness, weight, mesh size, and mineral and geological composition canbe utilized as inputs including time value of money data sets yieldingproject cash flows, debt service and internal rates of return.

FIG. 2A shows a collection of impoundments including an uncovered oruncapped capsule impoundment 100, containing sectioned capsuleimpoundments 122 inside of a mining quarry 200 with various elevationsof bench mining. FIG. 2B illustrates a single impoundment 122 withoutassociated conduits and other aspects merely for clarity. Thisimpoundment can be similar to that illustrated in FIG. 1 or any otherconfiguration. In some embodiments, it is envisioned that mining rubblecan be transferred down chutes 230 or via conveyors 232 to the quarrycapsule impoundments 100 and 122 without any need of mining haul trucks.

FIG. 3 shows the engineered permeability barriers 112 below capsuleimpoundment 100 with cap covering material or fill 302 on the sides andtop of capsule impoundment 100 to ultimately (following the process)cover and reclaim a new earth surface 300. Indigenous plants which mayhave been temporarily moved from the area may be replanted such as trees306. The constructed infrastructures of the present invention cangenerally be single use structures which can be readily and securelyshut down with minimal additional remediation. This can dramaticallyreduce costs associated with moving large volumes of spent materials.However, in some circumstances the constructed infrastructures can beexcavated and reused. Some equipment such as radio frequency (RF)mechanisms, tubulars, devices and emitters may be recovered from withinthe constructed impoundment upon completion of hydrocarbon recovery.

FIG. 4 shows computer means 130 controlling various property inputs andoutputs of conduits 118, 126, or 128 connected to heat source 134 duringthe process among the subdivided impoundments 122 within a collectiveimpoundment 100 to control heating of the permeable body. Heat can beoptionally a closed loop such that gases are returned to the heat sourcevia return conduits 135 or otherwise directed away from theimpoundments. Similarly, liquid and vapor collected from theimpoundments can be monitored and collected in tank 136 and condenser140, respectively. For example, liquid products can be collected via adrainage system (not shown) and stored in liquid collection tank 136.Vapor products from individual impoundments can be collected via asuitable gas collection system and directed to the condenser.Condensable products are typically high quality hydrocarbons, e.g.kerosene, jet fuels, or other high grade fuels, and can be storedseparately in condensables tank 141. Similarly, non-condensable portionscan be directed to other parts of the process or stored in tank 143. Asdescribed previously, the liquid and vapor products can be combined ormore often left as separate products depending on condensability, targetproduct, and the like. A portion of the vapor product can be condensedand combined with the liquid products in tank 136. However, much of thevapor product will be C4 and lighter gases which can be burned, sold orused within the process. For example, hydrogen gas may be recoveredusing conventional gas separation and used to hydrotreat the liquidproducts according to conventional upgrading methods, e.g. catalytic,etc. or the non-condensable gaseous product can be burned to produceheat for use in heating the permeable body, heating an adjacent ornearby impoundment, heating service or personnel areas, or satisfyingother process heat requirements. The constructed infrastructure caninclude thermocouples, pressure meters, flow meters, fluid dispersionsensors, richness sensors and any other conventional process controldevices distributed throughout the constructed infrastructure. Thesedevices can be each operatively associated with a computer such thatheating rates, product flow rates, and pressures can be monitored oraltered during heating of the permeable body. Optionally, in-placeagitation can be performed using, for example, ultrasonic generatorswhich are associated with the permeable body. Such agitation canfacilitate separation and pyrolysis of hydrocarbons from the underlyingsolid materials with which they are associated. Further, sufficientagitation can reduce clogging and agglomeration throughout the permeablebody and the conduits.

FIG. 5 shows how any of the conduits can be used to transfer heat in anyform of gas, liquid or heat via transfer means 510 from any sectionedcapsule impoundment to another. Then, cooled fluid can be conveyed viaheat transfer means 512 to the heat originating capsule 500, or heatoriginating source 134 to pick up more heat from capsule 500 to be againrecirculated to a destination capsule 522. Thus, various conduits can beused to transfer heat from one impoundment to another in order torecycle heat and manage energy usage to minimize energy losses.

In yet another aspect of the present invention, a hydrogen donor agentcan be introduced into the permeable body during the step of heating.The hydrogen donor agent can be any composition which is capable ofhydrogenation of the hydrocarbons and can optionally be a reducingagent. Non-limiting examples of suitable hydrogen donor agents caninclude synthesis gas, propane, methane, hydrogen, natural gas, naturalgas condensate, industrial solvents such as acetones, toluenes,benzenes, xylenes, cumenes, cyclopentanes, cyclohexanes, lower alkenes(C4-C10), terpenes, substituted compounds of these solvents, etc., andthe like. Further, the recovered hydrocarbons can be subjected tohydrotreating either within the permeable body or subsequent tocollection. Advantageously, hydrogen recovered from the gas products canbe reintroduced into the liquid product for upgrading. Regardless,hydrotreating or hydrodesulfurization can be very useful in reducingnitrogen and sulfur content in final hydrocarbon products. Optionally,catalysts can be introduced to facilitate such reactions. In addition,introduction of light hydrocarbons into the permeable body can result inreforming reactions which reduce the molecular weight, while increasingthe hydrogen to carbon ratio. This is particularly advantageous for usein the present invention due at least in part to high permeability ofthe permeable body, e.g. often around 30% void volume although voidvolume can generally vary from about 15% to about 40% void volume. Lighthydrocarbons which can be injected can be any which provide reforming torecovered hydrocarbons. Non-limiting examples of suitable lighthydrocarbons include natural gas, natural gas condensates, industrialsolvents, hydrogen donor agents, and other hydrocarbons having ten orfewer carbons, and often five or fewer carbons. Currently, natural gasis an effective, convenient and plentiful light hydrocarbon. Asmentioned previously, various solvents or other additives can also beadded to aid in extraction of hydrocarbon products from the oil shaleand can often also increase fluidity.

The light hydrocarbon can be introduced into the permeable body byconveying the same through a delivery conduit having an open end influid communication with a lower portion of the permeable body such thatthe light hydrocarbons (which are a gas under normal operatingconditions) permeate up through the permeable body. Alternatively, thissame approach can be applied to recovered hydrocarbons which are firstdelivered to an empty impoundment. In this way, the impoundment can actas a holding tank for direct products from a nearby impoundment and as areformer or upgrader. In this embodiment, the impoundment can be atleast partially filled with a liquid product where the gaseous lighthydrocarbon is passed through and allowed to contact the liquidhydrocarbon products at temperatures and conditions sufficient toachieve reforming in accordance with well known processes. Optionalreforming catalysts which include metals such as Pd, Ni or othersuitable catalytically active metals can also be included in the liquidproduct within the impoundment. The addition of catalysts can serve tolower and/or adjust reforming temperature and/or pressure for particularliquid products. Further, the impoundments of the present invention canbe readily formed at almost any depth. Thus, optimal reforming pressures(or recovery pressures when using impoundment depth as pressure controlmeasure for recovery from a permeable body) can be designed based onhydrostatic pressure due to the amount of liquid in the impoundment andthe height of the impoundment, i.e. P=ρgh. In addition, the pressure canvary considerably over the height of the impoundment sufficient toprovide multiple reforming zones and tailorable pressures. Generally,pressures within the permeable body can be sufficient to achievesubstantially only liquid extraction, although some minor volumes ofvapor may be produced depending on the particular composition of thepermeable body. As a general guideline, pressures can range from about 5atm to about 50 atm, although pressures from about 6 atm to about 20 atmcan be particularly useful. However, any pressure greater than aboutatmospheric can be used.

In one embodiment, extracted crude has fines precipitated out within thesubdivided capsules. Extracted fluids and gases can be treated for theremoval of fines and dust particles. Separation of fines from shale oilcan be accomplished by techniques such as, but not limited to, hot gasfiltering, precipitation, and heavy oil recycling.

Hydrocarbon products recovered from the permeable body can be furtherprocessed (e.g. refined) or used as produced. Any condensable gaseousproducts can be condensed by cooling and collection, whilenon-condensable gases can be collected, burned as fuel, reinjected, orotherwise utilized or disposed of. Optionally, mobile equipment can beused to collect gases. These units can be readily oriented proximate tothe control infrastructure and the gaseous product directed thereto viasuitable conduits from an upper region of the control infrastructure.

In yet another alternative embodiment, heat within the permeable bodycan be recovered subsequent to primary recovery of hydrocarbon materialstherefrom. For example, a large amount of heat is retained in thepermeable body. In one optional embodiment, the permeable body can beflooded with a heat transfer fluid such as water to form a heated fluid,e.g. heated water and/or steam. At the same time, this process canfacilitate removal of some residual hydrocarbon products via a physicalrinsing of the spent shale solids. In some cases, the introduction ofwater and presence of steam can result in water gas shift reactions andformation of synthesis gas. Steam recovered from this process can beused to drive a generator, directed to another nearby infrastructure, orotherwise used. Hydrocarbons and/or synthesis gas can be separated fromthe steam or heated fluid by conventional methods.

Although the methods and infrastructure of the present invention allowfor improved permeability and control of operating conditions,significant quantities of unrecovered hydrocarbons, precious metals,minerals, sodium bicarbonate or other commercially valuable materialsoften remain in the permeable body. Therefore, a selective solvent canbe injected or introduced into the permeable body. Typically, this canbe done subsequent to collecting the hydrocarbons, although certainselective solvents can be beneficially used prior to heating and/orcollection. This can be done using one or more of the existing conduitsor by direct injection and percolation through the permeable body. Theselective solvent or leachate can be chosen as a solvent for one or moretarget materials, e.g. minerals, precious metal, heavy metals,hydrocarbons, or sodium bicarbonate. In one specific embodiment, steamor carbon dioxide can be used as a rinse of the permeable body todislodge at least a portion of any remaining hydrocarbons. This can bebeneficial not only in removing potentially valuable secondary products,but also in cleaning remaining spent materials of trace heavy metal orinorganics to below detectable levels in order to comply with regulatorystandards or to prevent inadvertent leaching of materials at a futuredate.

More particularly, various recovery steps can be used either before orafter heating of the permeable body to recover heavy metals, preciousmetals, trace metals or other materials which either have economic valueor may cause undesirable problems during heating of the permeable body.Typically, such recovery of materials can be performed prior to heattreatment of the permeable body. Recovery steps can include, but are inno way limited to, solution mining, leaching, solvent recovery,precipitation, acids (e.g. hydrochloric, acidic halides, etc.),flotation, ionic resin exchange, electroplating, or the like. Forexample, heavy metals, bauxite or aluminum, and mercury can be removedby flooding the permeable body with an appropriate solvent andrecirculating the resulting leachate through appropriately designed ionexchange resins (e.g. beads, membranes, etc.).

Similarly, bioextraction, bioleaching, biorecovery, or bioremediation ofhydrocarbon material, spent materials, or precious metals can beperformed to further improve remediation, extract valuable metals, andrestoration of spent material to environmentally acceptable standards.In such bioextraction scenarios, conduits can be used to injectcatalyzing gases as a precursor which helps to encourage bioreaction andgrowth. Such microorganisms and enzymes can biochemically oxidize theore body or material or cellulosic or other biomass material prior to anore solvent extraction via bio-oxidation. For example, a perforated pipeor other mechanism can be used to inject a light hydrocarbon (e.g.methane, ethane, propane or butane) into the permeable body sufficientto stimulate growth and action of native bacteria. Bacteria can benative or introduced and may grow under aerobic or anaerobic conditions.Such bacteria can release metals from the permeable body which can thenbe recovered via flushing with a suitable solvent or other suitablerecovery methods. The recovered metals can then be precipitated outusing conventional methods.

Synthesis gas can also be recovered from the permeable body during thestep of heating. Various stages of gas production can be manipulatedthrough processes which raise or lower operating temperatures within theencapsulated volume and adjust other inputs into the impoundment toproduce synthetic gases which can include but are not limited to, carbonmonoxide, hydrogen, hydrogen sulfide, hydrocarbons, ammonia, water,nitrogen or various combinations thereof. In one embodiment, temperatureand pressure can be controlled within the permeable body to lower CO₂emissions as synthetic gases are extracted.

Hydrocarbon product recovered from the constructed infrastructures ofthe present invention can most often be further processed, e.g. byupgrading, refining, etc. Sulfur from related upgrading and refiningprocessing can be isolated in various constructed sulfur capsules withinthe greater structured impoundment capsule. Constructed sulfur capsulescan be spent constructed infrastructures or dedicated for the purpose ofstorage and isolation after desulfurization.

Similarly, spent hydrocarbonaceous material remaining in the constructedinfrastructure can be utilized in the production of cement and aggregateproducts for use in construction or stabilization of the infrastructureitself or in the formation of offsite constructed infrastructures. Suchcement products made with the spent shale may include, but are notlimited to, mixtures with Portland cement, calcium, volcanic ash,perlite, synthetic nano carbons, sand, fiber glass, crushed glass,asphalt, tar, binding resins, cellulosic plant fibers, and the like.

In still another embodiment of the present invention, injection,monitoring and production conduits or extraction egresses can beincorporated into any pattern or placement within the constructedinfrastructure. Monitoring wells and constructed geo membrane layersbeneath or outside of the constructed capsule containment can beemployed to monitor unwanted fluid and moisture migration outside ofcontainment boundaries and the constructed infrastructure.

Although a filled and prepared constructed infrastructure can often beimmediately heated to recover hydrocarbons, this is not required. Forexample, a constructed infrastructure which is built and filled withmined hydrocarbonaceous material can be left in place as a provenreserve. Such structures are less susceptible to explosion or damage dueto terrorist activity and can also provide strategic reserves ofunprocessed petroleum products, with classified and known properties sothat economic valuations can be increased and more predictable. Longterm petroleum storage often faces quality deterioration issues overtime. Thus, the present invention can optionally be used for long termquality insurance and storage with reduced concerns regarding breakdownand degradation of hydrocarbon products.

In still another aspect of the present invention, the high qualityliquid product can be blended with more viscous lower quality (e.g.lower API) hydrocarbon products. For example, kerogen oil produced fromthe impoundments can be blended with bitumen to form a blended oil. Thebitumen is typically not transportable through an extended pipelineunder conventional and accepted pipeline standards and can have aviscosity substantially above and an API substantially below that of thekerogen oil. The amount of blending can vary considerably depending onthe particular quality of bitumen and kerogen oils. However, as ageneral guideline the blended oil can be from 5% to 95% kerogen oil, insome cases from about 10% to about 40%, and in other cases from about50% to 80%, with substantially a remainder of the blended oil comprisingbitumen. By blending the kerogen oil and bitumen, the blended oil can berendered transportable without the use of additional diluents or otherviscosity or API modifiers. As a result, the blended oil can be pumpedthrough a pipeline without requiring additional treatments to remove adiluent or returning such diluents via a secondary pipeline.Conventionally, bitumen is combined with a diluent such as natural gascondensate or other low molecular weight liquids, to allow pumping to aremote location. The diluent is removed and returned via a secondpipeline back to the bitumen source. The present invention allows forelimination of returning diluent and simultaneous upgrading of thebitumen.

It is to be understood that the above-referenced arrangements areillustrative of the application for the principles of the presentinvention. Thus, while the present invention has been described above inconnection with the exemplary embodiments of the invention, it will beapparent to those of ordinary skill in the art that numerousmodifications and alternative arrangements can be made without departingfrom the principles and concepts of the invention as set forth in theclaims.

1. A method of recovering hydrocarbons from hydrocarbonaceous materials,comprising: a) forming a constructed permeability control infrastructurewhich defines a substantially encapsulated volume, said constructedpermeability control infrastructure having permeable side walls and asubstantially impermeable cap; b) introducing a comminutedhydrocarbonaceous material into the control infrastructure to form apermeable body of hydrocarbonaceous material; c) heating the permeablebody sufficient to remove hydrocarbons therefrom such that thehydrocarbonaceous material is substantially stationary during heating;and d) collecting the removed hydrocarbons.
 2. The method of claim 1,wherein the permeable side walls are undisturbed geological formation orcompacted earth.
 3. The method of claim 1, wherein the controlinfrastructure is formed within an excavated pit.
 4. The method of claim3, wherein the step of forming the control infrastructure includesexcavating a hydrocarbonaceous deposit or a non-hydrocarbon bearingformation using a crane-suspended excavator.
 5. The method of claim 1,wherein the control infrastructure is free-standing.
 6. The method ofclaim 1, wherein the mined hydrocarbonaceous material comprises oilshale, tar sands, coal, lignite, bitumen, peat, or combinations thereof.7. The method of claim 6, wherein the mined hydrocarbonaceous materialincludes a lower layer of tar sands and an upper layer of oil shale. 8.The method of claim 1, wherein the permeable body further comprises anadditive or biomass.
 9. The method of claim 1, wherein the permeablebody consists essentially of crushed hydrocarbonaceous material havingan average size from about 6 inches to about 2 feet.
 10. The method ofclaim 1, wherein the permeable body has a void space from about 10% toabout 40% a total volume of the permeable body.
 11. The method of claim1, further comprising the step of mining the hydrocarbonaceous materialfrom a remote location distinct from the control infrastructure.
 12. Themethod of claim 1, wherein the step of heating includes injecting heatedgases into the control infrastructure such that the permeable body isprimarily heated via convection as the heated gases pass throughout thepermeable body.
 13. The method of claim 1, wherein the constructedpermeability control infrastructure further includes a substantiallyimpermeable floor including a drainage system fluidly for removingliquid products from the encapsulated volume.
 14. The method of claim 1,wherein the permeable body further comprises a plurality of conduitsembedded within the permeable body, at least some of said conduits beingconfigured as heating pipes.
 15. The method of claim 14, wherein atleast a portion of the plurality of conduits are oriented substantiallyhorizontally.
 16. The method of claim 14, wherein the step of formingthe constructed infrastructure includes orienting at least a portion ofthe conduits along predetermined pathways prior to embedding theconduits within the permeable body.
 17. The method of claim 14, whereinthe heating conduits are fluidly coupled to a heat source and furthercomprising circulating a heating fluid in a closed loop through theheating conduits sufficient to prevent substantial mass transfer betweenthe heating fluid and the permeable body.
 18. The method of claim 14,wherein the step of heating heats the permeable body sufficientlyuniformly and within a temperature range sufficient to substantiallyavoid formation of carbon dioxide or non-hydrocarbon leachates.
 19. Themethod of claim 14, wherein the step of heating occurs over a time andwithin a temperature range sufficient to produce in situ solvent whichsupplements removal of the hydrocarbon from the permeable body.
 20. Themethod of claim 1, wherein the introducing of the comminutedhydrocarbonaceous material into the control infrastructure isaccomplished by low compaction conveying of the hydrocarbonaceousmaterial into the infrastructure.
 21. The method of claim 1, wherein theheating is accomplished by electrical resistive heating, fuel cell,solid oxide fuel cell, solar sources, wind sources, wave sources,hydrocarbon combustion, geothermal, nuclear power, or combinationthereof.
 22. The method of claim 21, wherein the heating is accomplishedby hydrocarbon combustion under stoichiometric conditions of fuel tooxygen.
 23. The method of claim 21, wherein the heating is accomplishedby a plurality of portable combustors each attached to a heating conduitembedded within the permeable body.
 24. The method of claim 1, furthercomprising introducing a hydrogen donor agent into the permeable bodyduring the step of heating, said hydrogen donor agent being capable ofhydrogenation of the hydrocarbons.
 25. The method of claim 24, whereinthe hydrogen donor agent is natural gas and conditions of pressure andtemperature are sufficient to cause reforming of the hydrocarbons toproduce an upgraded hydrocarbon product.
 26. The method of claim 1,further comprising collecting the removed hydrocarbons in a secondconstructed permeability control infrastructure to form a body of liquidhydrocarbon and introducing a hydrogen donor agent into the body ofliquid hydrocarbon, said hydrogen donor agent being capable of upgradingof the hydrocarbons.
 27. The method of claim 1, wherein the step ofcollecting the removed hydrocarbons includes collecting a liquid productfrom a lower region of the control infrastructure and collecting agaseous product from an upper region of the control infrastructure. 28.The method of claim 27, wherein collecting a gaseous product furthercomprises directing the gaseous product to a mobile gas collection unitproximate to the control infrastructure.
 29. The method of claim 27,further comprising combusting a fuel portion of the gaseous product toproduce heat.
 30. The method of claim 27, wherein the liquid product isa kerogen oil and further comprising blending the kerogen oil with anon-transportable bitumen to form a transportable blended oil.
 31. Themethod of claim 1, further comprising injecting a selective solvent intothe permeable body subsequent to collecting the hydrocarbons, saidselective solvent being a solvent for one or more target materials. 32.The method of claim 31, wherein the target materials comprise mineral,precious metal, hydrocarbons, or sodium bicarbonate.
 33. The method ofclaim 1, further comprising recovering heat from the permeable body andtransferring said heat to a second permeable body.
 34. The method ofclaim 1, further comprising circulating a heat transfer fluid throughoutthe permeable body after the heating to at least partially recover heatfrom the permeable body.
 35. The method of claim 34, wherein the heattransfer fluid consists essentially of water.
 36. The method of claim 1,wherein the comminuted hydrocarbonaceous material is crushed oil shaleand the heating is performed under time and temperature conditionssufficient to form a liquid hydrocarbon product having an API from about30 to about
 45. 37. The method of claim 1, further comprising the stepof monitoring earth surrounding the substantially encapsulated volumefor undesirable egress of gaseous or liquid materials into thesurrounding earth.
 38. A constructed permeability controlinfrastructure, comprising: a) a permeability control impoundmentdefining a substantially encapsulated volume wherein the permeabilitycontrol impoundment is undisturbed geological formations or compactedearth; b) a comminuted hydrocarbonaceous material within theencapsulated volume forming a permeable body of hydrocarbonaceousmaterial; and c) a heating device embedded within the permeable body forconvective heating thereof.
 39. The infrastructure of claim 38, whereinthe permeability control impoundment includes substantially permeableside walls, a substantially impermeable cap, and a substantiallyimpermeable floor.
 40. The infrastructure of claim 39, wherein theimpermeable cap is a compacted fill ceiling substantially covering thepermeable body, said compacted fill ceiling being supported by thepermeable body.
 41. The infrastructure of claim 38, wherein the controlinfrastructure is formed in direct contact with walls of an excavatedhydrocarbonaceous material deposit.
 42. The infrastructure of claim 41,further comprising at least one additional excavated hydrocarbonaceousmaterial deposit and wherein the comminuted hydrocarbonaceous materialis mined from an adjacent hydrocarbonaceous material deposit.
 43. Theinfrastructure of claim 38, wherein the control infrastructure isfreestanding.
 44. The infrastructure of claim 38, further comprising atleast one interior wall within the control infrastructure subdividingthe encapsulated volume.
 45. The infrastructure of claim 38, wherein thecomminuted hydrocarbonaceous material comprises oil shale, tar sands,coal, lignite, bitumen, peat, or combinations thereof.
 46. Theinfrastructure of claim 45, wherein the comminuted hydrocarbonaceousmaterial includes a lower layer of tar sands and an upper layer of oilshale.
 47. The infrastructure of claim 38, wherein the permeable bodyhas a void space from 10% to about 40% of a total volume of thepermeable body.
 48. The infrastructure of claim 38, further comprising agaseous heat source operatively connected to the permeability controlimpoundment and configured to direct a heated gas to the permeable bodyfor convective heating thereof.
 49. The infrastructure of claim 38,further comprising a plurality of conduits embedded within the permeablebody, at least some of the plurality of conduits being heating conduitsas the heating device.
 50. The infrastructure of claim 49, wherein atleast a portion of the plurality of conduits are oriented substantiallyhorizontally.
 51. The infrastructure of claim 38, further comprising aheat source thermally associated with the permeable body.
 52. Theinfrastructure of claim 51, wherein the heat source includes anelectrical resistive heater, fuel cell, solid oxide fuel cell, solarheater, wind generator, hydrocarbon combustor, geothermal, or nuclear.53. The infrastructure of claim 51, wherein the heating conduits arethermally coupled to the heat source and embedded in the permeable bodyto form a closed heating system having substantially no mass transferbetween the permeable body and heating fluids within the heatingconduits.
 54. The infrastructure of claim 38, further comprising amobile gas collection unit operatively connected to collect gaseousproduct from an upper region of the control infrastructure.
 55. Theinfrastructure of claim 38, further comprising a drainage systemassociated with the floor and operatively connected to collect liquidhydrocarbon product from a lower region of the control infrastructure.